Helmets with Facemask Gaskets

ABSTRACT

A helmet comprises a shell, a gasket, and a facemask. A recessed region is formed on an exterior surface of the shell of the helmet. The gasket is disposed on the recessed region of the shell. The facemask is disposed on the gasket.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a non-provisional application of, and claims priority to, U.S. Provisional Application No. 61/983,116, filed on Apr. 23, 2014 and titled “Face Mask Gasket,” which is incorporated by reference herein in its entirety.

BACKGROUND

Mild Traumatic Brain Injury (MTBI), commonly referred to as “a concussion,” is an injury that frequently occurs in contact sports, such as football. Sport-related brain injuries have been estimated to occur 1.6 to 3.8 million times every year. Additionally, it is estimated that some football players receive up to 1,500 head impacts per season. Although every impact may not result in MTBI, numerous impacts to the head can result in long-term brain damage through an impact induced neurodegenerative disease known as Chronic Traumatic Encephalopathy (CTE).

BRIEF DESCRIPTION OF THE DRAWINGS

Many aspects of the present disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, with emphasis instead being placed upon clearly illustrating the principles of the disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.

FIGS. 1A-1C are drawings of an example of a helmet according to various embodiments of the present disclosure.

FIG. 2 is a drawing of a shell of the helmet of FIGS. 1A-1C according to various embodiments of the present disclosure.

FIG. 3 is a drawing of a facemask of the helmet of FIGS. 1A-1C according to various embodiments of the present disclosure.

FIG. 4 is a drawing of a gasket of the helmet of FIGS. 1A-1C according to various embodiments of the present disclosure.

FIG. 5 is an exploded view of the helmet of FIGS. 1A-1C according to various regions of the present disclosure.

DETAILED DESCRIPTION

The present disclosure relates to helmets that protect a wearer's head and reduce the likelihood of the wearer experiencing Mild Traumatic Brain Injury (MTBI), Chronic Traumatic Encephalopathy (CTE), or other types of injuries. The helmet in some embodiments comprises a helmet shell, a facemask, and a gasket that is positioned between the helmet shell and the facemask. The gasket is configured to dissipate energy. Thus, when the facemask of the helmet impacts an object, a portion of the energy resulting from the impact is dissipated through the gasket, instead of being transferred to the wearer's head. Because the amount of energy that is transferred to the user's head is less than the amount that would otherwise be transferred if the helmet did not comprise the gasket, the helmet reduces the likelihood of the user experiencing various types of injuries.

In the following discussion, a general description of the system and its components is provided, followed by a discussion of the operation of the same.

With reference to FIGS. 1A-1C, shown is an example of a helmet 100 according to various embodiments of the present disclosure. The helmet 100 shown in FIGS. 1A-1C is embodied in the form of a football helmet. However, in alternative embodiments, the helmet 100 may be embodied in the form of other types of athletic helmets, such as hockey helmets, lacrosse helmets, etc. Additionally, the helmet 100 in some examples may be embodied in the form of a racing helmet, such as an automotive racing helmet, a motorbike racing helmet, etc. In addition, the helmet 100 in alternative examples may be embodied in the form of a tactical helmet, which may be used, for example, by law enforcement or military personnel. The helmet 100 in some embodiments is similar to embodiments described in U.S. Pat. No. 8,656,520, issued on Feb. 25, 2014 and titled “Athletic Helmet,” which is incorporated by reference herein in its entirety.

The helmet 100 shown in FIGS. 1A-1C comprises a shell 103, a liner 106, and a facemask 109. In addition, the helmet 100 comprises a gasket (not shown), which is described in further detail below. The helmet 100 absorbs energy from an impact that is applied to the helmet 100. Thus, the helmet 100 protects the wearer's head, neck, and back by providing shock absorbent properties in the event of an impact. In some embodiments, the helmet 100 also comprises a chin strap, such as a chin strap that is described in U.S. Pat. No. 6,381,757, issued on May 7, 2002 and titled “Inflatable Chin Strap for a Helmet,” which is incorporated by reference herein in its entirety.

The liner 106 is attached to the interior of the shell 103. The liner 106 provides cushioning for the wearer's head and absorbs impact forces on the helmet 100. The liner 106 in some embodiments comprises a visco-elastic foam that conforms to the wearer's head, thereby providing increased contact surface area and greater protection against impact forces. In some embodiments, the liner 106 is removable to, for example, facilitate cleaning or replacement of the liner 106.

With reference to FIG. 2, shown is the shell 103 of the helmet 100 according to various embodiments. The shell 103 may be constructed of a molded plastic, such as polycarbonate, a fiber-resin composite, or any other suitable material. The shell 103 comprises an exterior surface 113. The shell 103 also comprises side portions 116 a-116 b, a back portion 119, and a front portion 123. The side portions 116 a-116 b protect the sides of the wearer's head, including the user's ears. The back portion 119 protects the neck and back of the wearer's head. The front portion 123 of the shell 103 protects the front of the wearer's head.

The shell 103 also comprises a recessed region 126 along the portion of the exterior surface 113 that defines an opening for the wearer's face. As will be described in further detail below, a portion of the facemask 109 is positioned over the recessed region 126 of the shell 103. The exterior surface 113 of the shell 103 at the recessed region 126 is recessed relative to other portions of the exterior surface 113. In some embodiments, the exterior surface 113 of the shell 103 at the recessed region 126 is recessed by approximately 3-6 millimeters relative to other portions of the exterior surface 113. The recessed region 126 of the shell 103 may be formed along the front perimeter of the shell 103, as shown in FIG. 2.

As shown in FIG. 2, holes 129 a-129 f may be formed in the recessed region 126. Fasteners, such as rivets, bolts, screws, etc., may insert through the holes 129 a-129 f to retain the facemask 109 to the shell 103.

With reference to FIG. 3, shown is the facemask 109 of the helmet 100 according to various embodiments. The facemask 109 protects the wearer's face, including eyes, nose, mouth, etc. The facemask 109 shown in FIG. 3 is an open cage type of facemask 109. In other embodiments, the facemask 109 may be embodied in the form of other types of facemasks 109, such as a closed cage type of facemask 109. Also, various types of facemask configurations may be used in various embodiments. For example, Double Wire (DW) configuration, Single Wire (SW) configuration, Reinforced (R), or other types of facemask configurations may be used in various embodiments. In addition, various types of facemasks 109 may be used to provide various protection levels, such as Oral Protection Only (OPO), Nose and Oral Protection Only (NOPO), Eye Glass and Oral Protection (EGOP), etc.

The facemask 109 shown in FIG. 3 comprises a flange 133 that, when the facemask 109 is attached to the shell 103, is positioned over and aligns with the recessed region 126 of the shell 103. Holes 136 a-136 f are also formed in the flange 133. Fasteners, such as rivets, bolts, screws, etc., may insert through the holes 136 a-136 f to retain the facemask 109 to the shell 103.

With reference to FIG. 4, shown is an example of a gasket 400 for the helmet 100. The gasket 400 is configured to dissipate energy that is imparted to the facemask 109 when, for example, the helmet 100 is subjected to an impact. The gasket 400 in various embodiments may be compressible or incompressible. Such a gasket 400 may comprise elastomeric materials, such as foam, rubber, gel, polynorbornene, hydrogel, a visco-elastic polymeric solid, and/or any other suitable material. Such a suitable visco-elastic polymeric solid may comprise a SORBOTHANE polymer.

The gasket 400 is shaped so that the gasket 400 may be positioned over and aligned with the recessed region 126 of the shell 103. In addition, the gasket 400 is shaped so that the flange 133 of the facemask 109 may be positioned over and cover the gasket 400. In this way, the gasket 400 prevents the facemask 109 from making direct contact with the shell 103.

For the embodiment shown in FIG. 4, the gasket 400 is embodied in the form of a single component. In particular, the gasket 400 shown is formed from a single strip of material. However, in alternative embodiments, the gasket 400 may comprise multiple components that are separate relative to each other. For example, the gasket 400 may be formed from multiple strips of gasket material that are separate relative to each other. In one example, these multiple gasket portions may comprise flat circular rings, or any other suitable shape, that may be positioned along the recessed region 126 of the shell 103 and/or the flange 133 of the facemask 109.

In some embodiments, the gasket 400 is constructed by cutting a sheet of gasket material in the shape of the gasket 400. In other embodiments, the gasket 400 may be formed using injection molding processes or other construction techniques. In some embodiments, an adhesive may be disposed on the gasket 400 to facilitate assembly of the helmet 100. For example, an adhesive may be disposed on the surface 406 of the gasket 400 that contacts the facemask 109 and/or the surface 409 of the gasket 400 that contacts the shell 103.

Multiple holes 403 a-403 d are formed in the gasket 400. Fasteners, such as rivets, bolts, screws, etc., may insert through the holes 403 a-403 d. In some embodiments, the gasket 400 may comprise grommets that form the holes 403 a-403 d. Such grommets may be embedded within the gasket 400. Alternatively, the grommets may be attached to the surface 406 of the gasket 400 that contacts the facemask 109 or the surface 409 of the gasket 400 that contacts the shell 103.

With reference to FIG. 5, shown is an exploded view of a portion of the helmet 100, which shows the shell 103, the gasket 400, and the facemask 109. The liner 106 is not shown in FIG. 5. To assemble the helmet 100, the liner 106 may be inserted into the shell 103. Thereafter, the gasket 400 may be positioned on the recessed region 126 of the shell 103 so that the surface 409 makes direct contact with the recessed region 126 of the shell 103. As described above, the gasket 400 is shaped so that the gasket 400 aligns with the recessed region 126 of the shell 103. In some embodiments, the surface 409 comprises an adhesive to facilitate attaching the gasket 400 to the shell 103.

Next, the facemask 109 is attached to the shell 103. To this end, the facemask 109 may be positioned over the recessed region 126 of the shell 103 and the gasket 400. In particular, the flange 133 of the facemask 109 may be aligned with the recessed region 126 of the shell 103, so that the gasket 400 is positioned between the flange 133 and the recessed region 126 of the shell 103. Thereafter, fasteners, such as rivets, bolts, screws, etc., may be inserted into the respective holes 136 a-136 f in the facemask 109, holes 403 a-403 d in the gasket 400, and holes 129 a-129 e in the shell 103 to thereby retain the facemask 109 to the shell 103. In some embodiments, when the facemask 109 is attached to the shell 103, the exterior surface of the flange 133 of the facemask 109 is substantially flush with the exterior surface 113 of the shell 103.

The above-described embodiments of the present disclosure are merely examples of implementations to set forth a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described embodiments without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure. Disjunctive language used herein, such as the phrase “at least one of X, Y, or Z,” unless specifically stated otherwise, is used in general to present that an item, term, etc., may be either X, Y, or Z, or any combination thereof (e.g., X, Y, and/or Z). Thus, such disjunctive language is not generally intended to, and should not, imply that certain embodiments require at least one of X, at least one of Y, or at least one of Z to each be present. 

Therefore, the following is claimed:
 1. A helmet, comprising: a helmet shell comprising an exterior surface, wherein a recessed region is formed on the exterior surface of the helmet shell; a compressible gasket disposed in the recessed region of the helmet shell; and a facemask attached to the helmet shell and the compressible gasket, wherein the facemask is disposed on the compressible gasket.
 2. The helmet of claim 1, wherein the compressible gasket prevents the facemask from directly contacting the helmet shell.
 3. The helmet of claim 1, wherein the compressible gasket comprises an elastomeric gasket.
 4. The helmet of claim 1, further comprising a fastener that retains the facemask to the helmet shell, wherein the fastener extends through a hole that is formed in the compressible gasket.
 5. The helmet of claim 1, wherein the compressible gasket comprises a grommet for a fastener that retains the facemask to the helmet shell.
 6. The helmet of claim 1, wherein the facemask comprises a flange that directly contacts the compressible gasket.
 7. The helmet of claim 1, wherein the helmet comprises an athletic helmet.
 8. The helmet of claim 1, wherein the helmet comprises a football helmet.
 9. A helmet, comprising: a helmet shell; a facemask attached to the helmet shell; and means for dissipating energy from the facemask, wherein the means for dissipating the energy is disposed between the helmet shell and the facemask.
 10. The helmet of claim 9, wherein the means for dissipating the energy prevents the facemask from directly contacting the helmet shell.
 11. The helmet of claim 9, wherein the means for dissipating the energy comprises a gasket.
 12. The helmet of claim 9, wherein the means for dissipating the energy is embodied as a single component.
 13. The helmet of claim 9, wherein the means for dissipating the energy comprises a plurality of components that are separate relative to each other.
 14. The helmet of claim 9, wherein the means for dissipating the energy is disposed in a recessed region of the helmet shell.
 15. The helmet of claim 9, wherein the facemask comprises a flange that is disposed on the means for dissipating the energy.
 16. A method, comprising: disposing a gasket on a helmet shell; and attaching a facemask to the helmet shell so that the gasket is disposed between the helmet shell and the facemask; wherein the gasket is configured to dissipate energy from the facemask.
 17. The method of claim 16, further comprising inserting a fastener through a hole in the gasket to retain the facemask to the helmet shell.
 18. The method of claim 16, further comprising cutting the gasket from a sheet of gasket material.
 19. The method of claim 16, further comprising forming the gasket from a mold.
 20. The method of claim 16, wherein the gasket comprises at least one of a visco-elastic polymeric solid, linear or non-linear elastic, or a viscoplastic solid. 